Why does the glass tempering furnace consume a lot of energy?

As a glass tempering equipment, the glass tempering furnace requires electricity to provide power for both the heating and cooling systems during operation. Does the glass tempering furnace consume much electricity? It should be noted that there are many factors that affect the energy consumption of a glass tempering furnace, including the furnace sizes, furnace status, space utilization rate, glass performance requirements, etc. As a power consuming equipment, the profit of tempered glass is mostly occupied by electricity.

Here, as a manufacturer of glass tempering furnace, we would like to introduce the normal power consumption of the tempering furnace and the methods to reduce power energy consumption.

1. The energy consumption of the glass tempering furnace is mainly in the heating stage. The energy absorbed by a certain amount of glass heated to the softening point in the tempering furnace is constant, regardless of which heating technology used (radiation heating system or force convection heating system).

The use of a glass tempering furnace with a force convection system heating can effectively improve the heat absorption efficiency of glass, enabling it to complete the heating process faster than radiation heating, increase tempering output, and thus reduce energy consumption of the glass tempering furnace; And because the heating time of glass is shorter than that of radiation heating, the tempering quality of glass can be greatly improved;

1.1. Adopting multi working station inside the glass tempering furnace

The application of multi working station heating technology not only has significant energy-saving effects, but also greatly avoids the phenomenon of blast furnace in the glass tempering furnace. The so-called glass tempering furnace station refers to a station where glass of the same specification swings to and fro along the length direction of the furnace body in their respective areas, completes the preset time in their respective areas, and moves to the next station after heating the glass to the corresponding requirements. Although the manufacturing processes and structures of various tempering furnaces vary, the required temperature for heating the glass out of the furnace is indeed similar. For multi station tempering furnaces, it can greatly reduce the temperature difference inside the furnace, avoid the occurrence of glass cracking in the tempering furnace, reduce heat loss, and have a great promoting effect on achieving energy conservation and emission reduction.

1.2. Using frequency conversion technology (inverters for driving system and cooling system)

Frequency conversion/inverters technology is commonly used in blowers and ceramic roller drive, with relatively significant energy-saving effects. The blower using inverters technology can not only quickly meet the requirements of the cooling area air volume during the glass tempering process, but also generate sufficient wind pressure. This rapid cooling automatic air pressure and air volume regulation greatly saves electricity and reduces energy loss. The optimized matching of fan air volume, air pressure, and ceramic roller speed has also improved the quality of glass tempering.

2. Electricity consumption of glass tempering furnace

Firstly, the energy consumption of the glass tempering furnace is the energy consumed for processing a certain amount of glass. The best way to calculate the energy consumption of a glass tempering furnace is to measure the power consumption per square meter of glass produced continuously at a certain loading rate using a certain thickness of glass;

2.2. The hourly electricity consumption of a glass tempering furnace is related to the performance, power, operating level, wafer rate, product quality, and performance of the furnace. The unit power consumption for producing glass of different specifications and thicknesses is also different. For example, the energy consumption per square meter of 4mm glass is about 3.5-4 kilowatt hours, while the energy consumption per square meter of 6mm glass is 4.5-6 kilowatt hours (here, the power consumption refers to the hourly power consumption). A 2440 * 4200 tempering furnace consumes 500kW of electricity for one hour of operation without considering the specific blower model and furnace heating power difference?

3. Methods for reducing energy power consumption in glass tempering furnaces

3.1. Choose the furnace with relatively low energy consumption

The multi station heating technology of the tempering furnace has a certain effect on reducing energy consumption and improving the yield of tempered glass to a certain extent. The application of hollow ceramic rollers can reduce the amount of water and heat released inside the rollers compared to the use of solid ceramic rollers, reduce energy consumption, and make the glass surface heated more evenly, resulting in higher glass quality.

3.2. Select equipment suitable for product characteristics

The power consumption for producing tempered glass of different models and sizes also varies, and the power of equipment operation also affects the overall power consumption and product output. When choosing tempered furnace equipment, we should have a good understanding of product characteristics, choose according to the size, specifications, characteristics, etc. of the glass, balance the input-output ratio of power consumption and output, and reduce ineffective energy consumption.

3.3. Adjusting the temperature inside the heating furnace

During the heating process of a glass tempering furnace, it generally follows a mode where the upper temperature is set 5-10 degrees higher than the lower temperature, and the middle temperature is set 5-10 degrees lower than the two ends. This can ensure that the temperature difference of the glass in the effective heating area of the tempering furnace is around 5 ℃, ensuring the uniformity of glass heating.

3.4 Regular maintenance and upkeep

Regular maintenance and upkeep of the tempering furnace should be carried out based on the specific operation and production situation of the equipment to maintain good equipment operation and performance. Generally speaking, the roller path of the tempering furnace should be cleaned daily, maintained every six months, and inspected as a whole once a year. Maintaining good performance of equipment and spare parts can also help reduce power consumption.

3.5. Adjust parameters according to the product

There are differences in the required product tempering strength, product quality, and glass outlet surface temperature for different glass raw materials under process conditions such as furnace temperature, cooling air pressure, conveying speed and time, and quenching time during the tempering process. The above parameters should be adjusted according to different glass materials in a targeted manner to avoid ineffective energy consumption and reduce power consumption.

3.6. Improve yield

The losses during the production process also consume electricity, which is included in the overall power consumption of the finished product. Therefore, increasing the yield of tempered glass can reduce power consumption, which is also a key issue that tempered glass manufacturers are concerned about. Therefore, it requires us to master the operation and usage methods of glass tempering furnaces, as well as specific operating skills such as how to improve the flatness of glass tempering furnaces. It is helpful for us to improve the yield of tempered products.

Our company produces glass tempering furnace with various models & specifications to meet the requirements for tempering different types of glass.